Removal of Aromatics from Carbonylation Process

ABSTRACT

The invention relates to processes for removing aromatics from the reactants that are fed to a carbonylation reactor. The aromatics are removed using a guard bed that comprises an adsorbent.

CROSS REFERENCE TO RELATED APPLICATION

The present invention is a continuation-in-part of U.S. application Ser.No. 13/101,781, filed on May 5, 2011, the entire contents and disclosureof which is incorporated by reference.

FIELD OF THE INVENTION

The present invention is directed to a method for removing aromaticsfrom a reactant composition that is fed to a carbonylation process usinga guard bed that comprises an adsorbent.

BACKGROUND OF THE INVENTION

A widely used and successful commercial process for synthesizing aceticacid involves the catalyzed carbonylation of methanol with carbonmonoxide. The catalyst contains rhodium and/or iridium and a halogenpromoter, typically methyl iodide. The reaction is conducted bycontinuously bubbling carbon monoxide through a liquid reaction mediumin which the catalyst is dissolved. The reaction medium also comprisesmethyl acetate, water, methyl iodide and the catalyst. Conventionalcommercial processes for carbonylation of methanol include thosedescribed in U.S. Pat. Nos. 3,769,329, 5,001,259, 5,026,908, and5,144,068, the entire contents and disclosures of which are herebyincorporated by reference. Another conventional methanol carbonylationprocess includes the Cativa™ process, which is discussed in Jones, J. H.(2002), “The Cativa”L\f Processfor the Manl!facture (?fAcetic Acid,”Platinum Metals Review, 44 (3): 94-105, the entire content anddisclosure of which is hereby incorporated by reference. The reactionsolution is withdrawn from the reactor and purified to obtain aceticacid.

In the commercial production of acetic acid, there are several processesfor removing catalysts, promoters and impurities formed during thecarbonylation reaction when purifying the acetic acid. In addition toimpurities formed during the carbonylation process, some reactants,depending on their source and purity, may contain trace impurities thatmay pass through the carbonylation process. These “pass-through”impurities may be difficult to remove using conventional purificationtechniques. Thus, the resulting acetic acid may contain impurities thatform an off-specification product that is not suitable for the desiredend use.

As a result, the need exists for additional processes for removingimpurities, and in particular pass-through impurities, in the productionof acetic acid.

SUMMARY OF THE INVENTION

In a first embodiment, the present invention is directed to acarbonylation process for producing a carbonylation product having a lowaromatic content, the process comprising contacting a reactantcomposition that comprises (i) a reactant selected from the groupconsisting of methanol, methyl acetate, methyl formate, dimethyl ether,and mixtures thereof and (ii) an aromatic compound, preferably at least1 wppm the aromatic compounds, based on total weight of the reactantcomposition, with a guard bed that comprises an adsorbent to form ade-aromatic reactant composition, reacting carbon monoxide with thede-aromatic reactant composition in a reactor containing a reactionmedium to produce a reaction solution comprising acetic acid, andwherein the reaction medium comprises water, acetic acid, methylacetate, methyl iodide, and a catalyst, and withdrawing a reactionsolution from the reactor, wherein the reaction solution issubstantially free of aromatic compounds. In one embodiment, theadsorbent comprises activated carbon, zeolites, activated amorphousclays, metal oxides, or silicaceous adsorbents. At least 6 milligrams ofthe adsorbent may be used for each gram of the reactant composition. Inone embodiment, the aromatic compound is selected from the groupconsisting of benzene, toluene, xylenes, ethylbenzene, naphthalene,benzene derivatives, and mixtures thereof In one embodiment, thede-aromatic reactant composition comprises less than 40 wppm thearomatic compounds, based on total weight of the de-aromatic reactantcomposition, and has a lower concentration of the aromatic compoundsthan the reactant composition. In one embodiment, at least 40% of thearomatic compounds are removed by the guard bed.

In a second embodiment, the present invention is directed to acarbonylation process for producing a carbonylation product having a lowaromatic content, the process comprising measuring a concentration ofaromatic compounds in a reactant composition, wherein the reactant isselected from the group consisting of methanol, methyl acetate, methylformate, dimethyl ether, and mixtures thereof, contacting the reactantcomposition with a guard bed that comprises an adsorbent when themeasured concentration of aromatic compounds is more than 1 wppm to forma de-aromatic reactant composition having less than 40 wppm, providedthat the concentration of the aromatic compounds of the de-aromaticreactant composition is less than that the concentration of the aromaticcompounds of the reactant composition, reacting carbon monoxide with thede-aromatic reactant composition in a reactor containing a reactionmedium to produce a reaction solution comprising acetic acid, andwherein the reaction medium comprises water, acetic acid, methylacetate, methyl iodide, and a catalyst, and withdrawing a reactionsolution from the reactor, wherein the reaction solution issubstantially free of aromatic compounds. In one embodiment, thearomatic compounds are measured using an on-line analyzer selected fromthe group consisting of gas chromatography, and UV spectrophotometry. Inone embodiment, the process further comprises adding a fresh reactant tothe reactant composition prior to the guard bed, wherein the freshreactant comprises less aromatic compounds than the reactantcomposition.

In a third embodiment, the present invention is directed to acarbonylation process for contacting a reactant composition thatcomprises (i) a reactant selected from the group consisting of methanol,methyl acetate, methyl formate, dimethyl ether, and mixtures thereof,(ii) an aromatic compound, and (iii) an amine, with a guard bed thatcomprises an adsorbent to form a de-aromatic reactant composition,contacting the de-aromatic reactant composition with an exchange resin,preferably a sulfonated styrene-divinylbenzene copolymer, to produce apurified de-aromatic reactant composition having a reduced aminecontent, reacting carbon monoxide with the purified de-aromatic reactantcomposition in a reactor containing a reaction medium to produce areaction solution comprising acetic acid, and wherein the reactionmedium comprises water, acetic acid, methyl acetate, methyl iodide, anda catalyst, and withdrawing a reaction solution from the reactor,wherein the reaction solution is substantially free of aromaticcompounds and amine compounds. In one embodiment, the purifiedde-aromatic reactant composition comprises less than 1 wppm amine, basedon total weight of the purified de-aromatic reactant composition. Thereactant composition may comprise less than 100 wppm of the amine, basedon total weight of the reactant composition.

BRIEF DESCRIPTION OF DRAWINGS

The invention is described in detail below with reference to theappended drawings, wherein like numerals designate similar parts.

FIG. 1 illustrates a carbonylation process having a guard bed accordingto an embodiment of the present invention.

FIG. 2 illustrates a carbonylation section having a guard bed and anexchange resin for the reactant feed stream according to an embodimentof the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention generally relates to acetic acid production bymethanol carbonylation under low water conditions. The methanol reactantcompositions fed to the carbonylation process may contain, depending ongrade, low levels of impurities, including one or more aromatic and/oramine compounds. The aromatic compounds may be selected from the groupconsisting of benzene, toluene, xylenes, ethylbenzene, naphthalene,other benzene derivatives, and mixtures thereof Typically, the aromaticcompounds may be contaminants in the methanol reactant compositioncaused, for example, by transporting the methanol reactant in a trailer,container, pipe, or barge that previously contained a petrochemical or acompound other than the methanol reactant. The aromatic compounds may bepresent in amounts of at least 1 wppm, e.g., at least 50 wppm or atleast 75 wppm. In terms of ranges, the aromatic compounds may be presentin amounts from 1 to 800 wppm, e.g., from 50 to 500 wppm, or from 50 to100 wppm.

Such aromatic compounds are difficult to separate from acetic acid andthus additional purification after the carbonylation process may not beeffective in removing the aromatic compounds. As a result, the aromaticcompounds may pass through the acetic acid separation train along withthe acetic acid, resulting in off-spec acetic acid product. In oneembodiment, a guard bed that comprises an adsorbent is used to remove amajority of the aromatic compounds from the reactant composition that isfed to the carbonylation reactor. The resulting de-aromatic reactantcomposition has a lower aromatic concentration than the reactantcomposition that is fed to the guard bed. For example, the guard bed mayremove at least 40% of the aromatic compounds from the reactants, e.g.,at least 60%, at least 75% or at least 90%.

The adsorbents for the guard beds are preferably suited for removingaromatic compounds in the liquid phase. Suitable adsorbents may include,for example, activated carbon, zeolites, activated amorphous clays,metal oxides (iron oxide, zirconium oxides, alumina, titania), orsilicaceous adsorbents, (silicon oxide or silica gel). The adsorbent mayhave a surface area, as determined by nitrogen gas absorption, that isat least 100 m²/g, e.g., at least 250 m²/g or at least 500m²/g. Morepreferably, activated carbon is used as the adsorbent. Activated carbonmay be produced from a variety of carbonaceous raw materials, such ascoconut shells, nutshells, coal, and lignite. Granular activated carbonmay be used in a guard bed that has a 20×40, 12×40, 8×20, 8×30 size. Inone embodiment, at least 6 milligrams of absorbent may be used for eachgram of the reactant composition that passes through the guard bed, andmore preferable at least 10 milligrams or at least 100 milligrams. Thede-aromatic reactant composition that exits the guard bed may have anaromatic concentration of less than 40 wppm, e.g., less than 30 wppm orless than 20 wppm. In terms of ranges, the aromatic concentration in thede-aromatic reactant composition may range from 0.1 wppm to 40 wppm,e.g., from 0.1 to 30 wppm or from 0.1 to 20 wppm. In some embodiments,the guard bed may be capable of removing substantially all of thearomatic compounds from the reactant composition. Removing the aromaticcompounds from the reactant composition reduces the aromaticconcentration of the reaction solution from the carbonylation reactor sothat the reaction solution also comprises less than 40 wppm aromaticcompounds.

One problem with aromatic compounds in the reactant composition is thatthey may not be detected until the acetic acid is being used, e.g., as astarting material for synthesis of another chemical, such as vinylacetate. In one embodiment, prior to the reactant composition enteringthe carbonylation reactor, a portion of the reactant composition passedthrough an on-line gas chromatograph or UV spectrophotometer to monitoraromatic concentration.

In FIG. 1, a reactant composition, preferably methanol, in line 101 isfed to the carbonylation process 100. A gas chromatograph 102 detectsthe aromatic concentration of the reactant composition in line 101. Whenthe aromatic concentration is low, e.g., less than 0.1 wppm, thereactant composition, or a portion thereof, may be directed directly tocarbonylation reactor 110 via line 104. When the aromatic concentrationis greater than 0.1 wppm, and more preferably greater than 50 wppm, thereactant composition is directed to line 105. In one embodiment,reactant composition, or a portion thereof, in line 105 may pass throughguard bed 103 to remove the aromatic compounds using an adsorbent. Guardbed 103 is a fixed bed in FIG. 1. In other embodiments, guard beds maycomprise a fluidized bed, or moving bed. Single or multiple beds may beused, in series and/or in parallel. Guard bed 103 may be any practicalsize and preferably is sized so that the pressure drop across the bed isless than 100 kPa, e.g., less than 75 kPa or less than 50 kPa. Guard bed103 optionally may operate at a temperature from 00 C to 40 OC, e.g.,from 15° C. to 30° C. In one embodiment, guard bed 103 is adjacent to aninlet for reactor 110. The adsorption of aromatic compounds isexothermic and the adsorbent should be sufficiently durable so as towithstand the exothermic temperature increase.

In another embodiment, the reactant composition, or a portion thereof,in line 105 may be diluted with another reactant composition via stream106 that is substantially free of aromatic compounds. Without beingbound by theory, when the concentration of aromatic compounds in thereactant composition is more than 50 wppm, guard bed 103 may beinefficient in removing the aromatic compounds and thus it may be moreeffective to dilute the reactant composition so long as a source of thereactant composition that is substantially free of aromatics isavailable. In some exemplary embodiments, stream 106 may comprise morethan 50 wppm aromatic compounds, more than 75 wppm aromatic compounds ormore than 100 wppm aromatic compounds. In some embodiments, not shown,the reactant composition may be diluted and then passed to guard bed103.

The resulting de-aromatic reactant composition in line 107 that exitsguard bed 103 and/or is diluted with stream 106 may be fed directly tocarbonylation reactor 110 as shown in FIG. 1.

The rate of flow of reactant composition 101 through guard bed 103during removal of aromatic compounds and corrosive metals, in general,may vary from 0.8 to 80 bed volumes per hour (BV/hr), e.g., from 1 to 35BV/hr or more preferably from 1 to 25 BV/hr. In an exemplary embodiment,2.5 to 3 BV/hr may provide sufficient contact time for the adsorption ofaromatic compounds.

In one embodiment, guard bed 103 may be regenerated by switching thefeed to the bed and passing a solution that desorbs the aromaticcompounds. The aromatic compounds are completely removed from the bedprior to switching the reactant composition feed. Regenerating mayinclude thermal, solvent, and/or chemical regeneration, including wetair oxidation (WAO). Thermal regeneration, at temperature from 500° C.to 900° C., and WAO regenerate of the bed may be accompanied bysimultaneous destruction of the adsorbed compounds from the porousstructure. Chemical or solvent regeneration may use a regenerant, suchas methanol, ethanol, acetone, or formic acid, along with water rinsing.

In addition to aromatic compounds, the methanol reactant composition mayalso contain one or more amine compounds. Unlike aromatic compounds,amines in the methanol reactant composition may be derived from themethanol synthesis process. The amine compounds may build up in thecarbonylation process and, in particular, in the carbonylation reactorand accompanying flasher. Amine compounds tend to form inorganic aminesalts, which tend to build up in the reactor and/or flasher. As aresult, corrosion tends to increase in the reactor and associatedflasher, resulting in additional formation of corrosion metals. Thepresence of additional corrosion metals requires further processing tomaintain a low concentration of corrosion metals in the reactor and/orflasher. Thus, the presence of amine compounds presents operabilityissues that may be difficult to control and may lead to inefficientproduction.

One difficulty in removing amine compounds from a carbonylation processstream is that other impurities, in particular corrosion metalcontaminants, tend to dominate impurity removal dynamics. Typically,corrosion metal contaminants are removed from process streams usingexchange resins. In some exemplary cases, acid solvents such as aceticacid may be added to the exchange resin to improve removal efficiency ofcorrosion metal contaminants. The acidic environment may favor removalof corrosion metal contaminants. However, favoring the removal ofcorrosion metals contaminants tends to reduce the ability of theexchange resins to remove other impurities such as amine compounds.Previous efforts have focused on removing corrosion metal contaminantsusing exchange resins, but have failed to recognize the need to removeother impurities such as the aforementioned aromatic and/or aminecompounds.

In one embodiment, the processes of the present invention overcome theproblems associated with the presence of aromatic and/or amine compoundsand the removal of the amine compounds from carbonylation processstreams.

In particular for amines, the present invention addresses problemsrelating to removal of amine compounds from one or more carbonylationprocess streams that also contain corrosion metal contaminants.Generally, process streams that contain corrosion metal contaminants andamine compounds are acidic. The typical acidic conditions in an exchangeresin favor binding of the corrosion metal contaminants over aminecompounds. Thus, the exchange resins would be ineffective in removingamine compounds in an acidic environment. In some embodiments theacidity within the exchange resin is reduced by mixing the processstream, containing corrosion metal contaminants and amine compounds,with a slipstream to form an aqueous stream having a water concentrationof greater than 50 wt. %, e.g., greater than 60 wt. %, greater than 75wt. % or greater than 85 wt. %. In terms of ranges, the aqueous streammay have a water concentration from 50 wt. % to 90 wt. %, e.g., from 50wt. % to 85 wt. % or from 60 wt. % to 85 wt. %. The aqueous stream maycreate a weakly acidic environment, optionally having a pH above about4.5, or a non-acidic environment in the exchange resin. The waterconcentration of the aqueous stream may be controlled by mixing aslipstream with the process stream, or by directly feeding theslipstream to the exchange resin, to dilute the process streamcontaining corrosion metal contaminants and amine compounds. Multipleslipstreams may be mixed with the process stream, provided that theaqueous stream has a high water concentration. Using the aqueous stream,the removal of amine compounds may be improved, even in the presence ofcorrosion metal contaminants.

The slipstream may comprise methanol, water, methyl acetate, methyliodide or a mixture thereof In one embodiment, the slipstream maycomprise methanol, water, or mixtures thereof Preferably, the slipstreamcomprises water and a minor amount of organics. Also, the slipstream maycomprise acetic acid, e.g., amounts less than 20 wt. %, optionally lessthan 10 wt. % or less than 5 wt. %. In one embodiment, the slipstreammay be a dilute acetic acid stream. The slipstream may be obtained fromone or more of the process stream within the system. In addition, theslipstream, in some embodiments, may be obtained from a portion of thereactant feed stream. The slipstream may be added to the process streambefore contacting the exchange resin or may be added directly to theexchange resin.

In some embodiments of the present invention, the term “process stream”refers to any stream separated during purification that is retained inthe carbonylation process. In one embodiment, aromatic compounds areremoved from the reactant composition fed to the carbonylation reactorand not the carbonylation process stream. Generally, waste streams thatare purged or the resultant acetic acid product stream are not referredto as process streams. The process stream(s) may be recycled, directlyor indirectly, to the carbonylation reactor. In one embodiment, one ormore process stream may be treated with an exchange resin to removecorrosion metal contaminants and amine compounds. Also, some processstream(s) may be used as slipstream(s) to form the aqueous stream thatcontacts the exchange resin. In these cases, the process stream used toform the aqueous stream is different from the process stream treated viathe exchange resin.

Corrosion metal contaminants, in particular, iron, nickel, chromium andmolybdenum may be present in any of the process streams of thecarbonylation process. In general, these corrosion metal contaminantshave an adverse effect on the acetic acid production rate and theoverall stability of the process. Therefore, an ion exchange resin isplaced within the carbonylation process to remove these corrosion metalcontaminants, as well as amine compounds, from the process streams.

Returning to FIG. 1, de-aromatic reactant composition in line 107 andcarbon monoxide in line 108 are fed to carbonylation reactor 110. Areaction solution in line 111 is withdrawn and fed to flasher 112. Acatalyst solution process stream 113 is withdrawn from the base offlasher 112, and a portion thereof is passed through exchange resin bed114 containing the exchange resin via line 125. The exiting stream isrecycled via line 115 to reactor 110. It should be understood, that anyof the process streams can be treated via the ion exchange resin toremove amine compounds and/or metal contaminants therefrom. Processstream 113 should be at a temperature, such as less than 120° C., thatdoes not deactivate the resin. If necessary process stream 113 may becooled.

The present invention may be applied in any suitable methanolcarbonylation process. Exemplary carbonylation processes that may beused with embodiments of the present invention include those describedin U.S. Pat. Nos. 7,223,886, 7,005,541, 6,657,078, 6,339,171, 5,731,252,5,144,068, 5,026,908, 5,001,259, and 4,994,608, and U.S. Pub. Nos.2008/0287706, 2008/0293966, 2009/0107833, and 2009/0270651, thedisclosures of which are hereby incorporated by reference. The exemplarycarbonylation system depicted herein may also include further systemsand components that may be used with embodiments of the presentinvention include those described in these patents. It should beunderstood that the carbonylation system shown in the figures isexemplary and other components may be used with the scope of the presentinvention. The methanol carbonylation process may comprise acarbonylation section and a purification section. The embodiments of thepresent invention are not limited by the configuration of thecarbonylation or purification sections. Thus, any suitable purificationsection may be used in combination with any of the embodiments of thepresent invention.

In an exemplary carbonylation process as shown in FIG. 1, carbonmonoxide is fed via stream 108 to a lower portion of reactor 110. Otherreactants are similarly fed via stream 107. Preferably, these reactantsare substantially free of aromatic and/or amines compounds, which havebeen removed by at least one of guard bed 103 and/or exchange resin 114.Reactant composition in stream 107 supplies to reactor 110 at least onereactant comprising methanol, methyl acetate, methyl formate, dimethylether, and/or mixtures thereof In preferred embodiments, reactantcomposition in stream 107 supplies methanol and methyl acetate.Optionally, reactant composition in line 101 may be connected to one ormore vessels (not shown) that store fresh reactants for thecarbonylation process. Due to containments in those vessels, thearomatic compounds may be present in reactant composition 101 whentransferred to process 100. In addition, there may be a methyl iodidestorage vessel (not shown) and/or catalyst vessel (not shown) connectedto reactor 110 for supplying fresh methyl iodide and catalyst as neededto maintain reaction conditions. In other embodiments, all or some ofthe methanol and/or methanol derivatives supplied to reactor 110 may bein the form of scrubbed methanol from another location in the system oras a product or by-product of another system.

One or more process streams from carbonylation process 100 may berecycled to reactor 110. In some embodiments, recycle feed streamscomprising the reaction medium components, e.g., residual/entrainedcatalyst, or acetic acid, are directed to the reactor. Preferably, thereare multiple process streams that are recycled and fed, in combinationor separately, to reactor 110. For example, one or more process streamsfrom purification section 120 may be fed to reactor 110. Preferably, therecycled process streams are introduced in the lower portion of reactor110.

In certain embodiments of the invention, reactant composition in line107 comprises methanol and/or methanol derivatives. Suitable methanolderivatives include methyl acetate, dimethyl ether, methyl formate, andmixtures thereof In one embodiment, a mixture of methanol and methanolderivatives is used as a reactant in the process of the presentinvention. Preferably, methanol and/or methyl acetate are used asreactants. At least some of the methanol and/or methanol derivativeswill be converted to, and hence be present as, methyl acetate in thereaction medium by reaction with acetic acid product or solvent. Theconcentration of methyl acetate in the reaction medium is preferably inthe range from 0.5 wt. % to 70 wt. %, e.g., from 0.5 wt. % to 50 wt. %,or from 1 wt. % to 35 wt. %, of the total weight of the reaction medium.

In embodiments of the present invention, methanol fed to thecarbonylation reaction, after the aromatic compounds are reduced and/orremoved, may also contain one or more amine compounds. Conventionalacetic acid production processes used higher grades of methanol, whichlimits the reactant supply sources and increases costs of production.Lower grades of methanol may contain higher amounts of amine compounds.Even higher grades of methanol may contain amine compounds. For example,even 1 wppm of trimethylamine may be sufficient to give methanol adistinct odor. Also, some amine compounds may be present in the reactionmedium. The amine compounds include alkyl amines, aryl amines,heterocyclic amines, and mixtures thereof Alkyl and aryl amines mayinclude trimethylamine, triethylamine, dimethylethyl amine,diethylmethyl amine, diethylpropylamine, tri-n-propylamine,triisopropylamine, ethyldiisopropylamine, tri-n-butylamine,triisobutylamine, tricyclohexylamine, ethyldicyclohexylamine,N,N-dimethylaniline, N,N-diethylaniline, and benzyldimethylamine.Heterocyclic amines include piperidines, piperazines, pyridines,pyridazines, pyrazines, pyrimidines, triazines, pyrrolidines, pyrroles,pyrazoles, pyrazolines, pyrazolidines, imidazolines, imidazolidines,imidazoles, and triazoles, and substituted heterocyclic compoundsthereof The amine compounds may also comprise diamines, triamines, andtetramines, such as tetramethylhexamethylendiamine,tetramethylethylendiamine, tetramethylpropylendiamine,tetramethylbutylendiamine, pentamethyldiethyltriamine,pentaethyldiethylentriamine, pentamethyldipropylentriamine,tetramethyldiaminomethane, tetrapropyldiaminomethane,hexamethyltriethylentetramine, hexamethyltripropylenetetramine, anddiisobutylentriamine. The amine present in the methanol feed streams mayvary depending on the grade of the methanol and the type of impurity. Inone embodiment, the methanol feed comprises less than 100 wppm amine,based on nitrogen content, e.g., less than 20 wppm or less than 1 wppm.In terms of ranges, the methanol feed stream comprises from 0.1 to 100wppm amine compounds, based on nitrogen content, e.g., from 0.5 to 50wppm or from 1 to 20 wppm.

Carbon monoxide feed stream 108 may be essentially pure or may containsmall amounts of inerts and impurities such as carbon dioxide, methane,nitrogen, hydrogen, noble gases, water and C₁ to C−1 paraffinichydrocarbons. The presence of hydrogen in the carbon monoxide generatedin situ by the water gas shift reaction is preferably kept low (e.g.,less than 1 bar partial pressure or less than 0.5 bar partial pressure),as its presence may result in the formation of hydrogenation products.The partial pressure of carbon monoxide in the reaction is preferably inthe range from 1 bar to 70 bar, e.g., from 1 bar to 35 bar, or from 1bar to 15 bar.

In some embodiments of the invention, within reactor 110, methanol isreacted with carbon monoxide in a homogeneous catalytic reaction systemcomprising a reaction solvent, methanol and/or methanol derivatives, aGroup VIII catalyst, at least a finite concentration of water andoptionally an iodide salt.

Suitable Group VIII catalysts include rhodium and/or iridium catalysts.When a rhodium catalyst is used, the rhodium catalyst may be added inany suitable form such that rhodium is in the catalyst solution as anequilibrium mixture including [Rh(C0)2br anion, as is well known in theart. Iodide salts optionally maintained in the reaction mixtures of theprocesses described herein may be in the form of a soluble salt of analkali metal or alkaline earth metal or a quaternary ammonium orphosphonium salt. In certain embodiments, the catalyst co-promoter islithium iodide, lithium acetate, or mixtures thereof The saltco-promoter may be added as a non-iodide salt that will generate aniodide salt. The iodide catalyst stabilizer may be introduced directlyinto the reaction system. Alternatively, the iodide salt may begenerated in situ since under the operating conditions of the reactionsystem, a wide range of non-iodide salt precursors will react withmethyl iodide to generate the corresponding co-promoter iodide saltstabilizer. For additional detail regarding rhodium catalysis and iodidesalt generation, see U.S. Pat. Nos. 5,001,259, 5,026,908 and 5,144,068,the entireties of which are hereby incorporated by reference.

When an iridium catalyst is used, the iridium catalyst may comprise anyiridium-containing compound that is soluble in the reaction medium. Theiridium catalyst may be added to the reaction medium for thecarbonylation reaction in any suitable form that dissolves in thereaction medium or is convertible to a soluble form. Examples ofsuitable iridium-containing compounds that may be added to the reactionmedium include: IrCh, Irh, IrBr3, [Ir(C0)2I]2, [Ir(C0)2Cl]2,[Ir(C0)2Br]2, [Ir(C0)2I2rH+, [Ir(COf2Br2rH+, [Ir(C0)2I-lrH+,[Ir(CH3)h(C0)2rH+, Ir-l(C0)12, IrCh.3H20, IrBr3.3H20, Ir-l(C0)12,iridium metal, Ir203, Ir(acac)(C0)2, Ir(acac)3, iridium acetate,[Ir30(0Ac)₆(H2O)3][OAc] and hexachloroiridic acid [H2IrCl₆].Chloride-free complexes of iridium such as acetates, oxalates andacetoacetates are usually employed as starting materials. The iridiumcatalyst concentration in the reaction medium is generally in the rangeof 100 to 6000 wppm. The carbonylation of methanol utilizing iridiumcatalyst is well known and is generally described in U.S. Pat. Nos.5,942,460, 5,932,764, 5,883,295, 5,877,348, 5,877,347 and 5,696,284, theentireties of which are hereby incorporated by reference.

Other promoters and co-promoters may be used as part of the catalyticsystem of the present invention, as described in EP0849248, the entiretyof which is hereby incorporated by reference. Suitable promoters areselected from ruthenium, osmium, tungsten, rhenium, zinc, cadmium,indium, gallium, mercury, nickel, platinum, vanadium, titanium, copper,aluminum, tin, antimony, and are more preferably selected from rutheniumand osmium. Specific co-promoters are described in U.S. Pat. No.6,627,770, the entirety of which is incorporated herein by reference.

A promoter may be present in an effective amount up to the limit of itssolubility in the reaction medium and/or any liquid process streamsrecycled to the reactor from the purification and acetic acid recoverystage. When used, the promoter is suitably present in the reactionmedium at a molar ratio of promoter to metal catalyst of 0.5:1 to 15:1,preferably 2:1 to 10:1, more preferably 2:1 to 7.5:1. A suitablepromoter concentration is 400 to 5000 wppm.

A halogen co-catalyst/promoter is generally used in combination with theGroup VIII metal catalyst component. Methyl iodide is a preferred as thehalogen promoter. Preferably, the concentration of halogen promoter inthe reaction medium is in the range 1 wt. % to 50 wt. %, and preferably2 wt. % to 30 wt. %.

The halogen promoter may be combined with a salt stabilizer/co-promotercompound, which may include salts of a metal of Group lA or Group IIA,or a quaternary ammonium or phosphonium salt. Particularly preferred areiodide or acetate salts, e.g., lithium iodide or lithium acetate.

Water may be formed in situ in the reaction medium, for example, by theesterification reaction between methanol reactant and acetic acidproduct. In some embodiments, water is introduced to reactor 110together with or separately from other components of the reactionmedium. Water may be separated from the other components of reactioncomposition withdrawn from reactor 110 and may be recycled in controlledamounts to maintain the required concentration of water in the reactionmedium. Preferably, the concentration of water maintained in thereaction medium is in the range from 0.1 wt. % to 16 wt. %, e.g., from 1wt. % to 14 wt. %, or from 1 wt. % to 3 wt. % of the total weight of thereaction composition.

In accordance with a preferred carbonylation process of the presentinvention, the desired reaction rates are obtained even at low waterconcentrations by maintaining, in the reaction medium, an ester of thedesired carboxylic acid and an alcohol, desirably the alcohol used inthe carbonylation, and an additional iodide ion that is over and abovethe iodide ion that is present as hydrogen iodide. An example of apreferred ester is methyl acetate. The additional iodide ion isdesirably an iodide salt, with lithium iodide being preferred. It hasbeen found, as described in U.S. Pat. No. 5,001,259, that under lowwater concentrations, methyl acetate and lithium iodide act as ratepromoters only when relatively high concentrations of each of thesecomponents are present and that the promotion is higher when both ofthese components are present simultaneously. The absolute concentrationof iodide ion content is not a limitation on the usefulness of thepresent invention.

In reactor 110 the reaction medium is maintained, preferablyautomatically, at a predetermined level. This predetermined level mayremain substantially constant during normal operation. Into reactor 110,methanol, carbon monoxide, and sufficient water may be continuouslyintroduced as needed to maintain at least a finite concentration ofwater in the reaction medium. In some embodiments, carbon monoxide iscontinuously introduced into reactor 110. Carbon monoxide feed 108 isintroduced at a rate sufficient to maintain the desired total reactorpressure. The temperature of reactor 110 may be controlled using heatexchangers in a pump around loop.

Acetic acid is typically manufactured in a liquid phase reaction at atemperature from 160° C. to 220° C. and a total pressure from 20 bar to50 bar. In some embodiments of the invention, reactor 110 is operated ata temperature from 150° C. to 250° C., e.g., from 155° C. to 235° C., orfrom 160° C. to 220° C. The pressure of the carbonylation reaction ispreferably from 10 to 200 bar, more preferably 10 to 100 bar and mostpreferably 15 to 50 bar.

A gaseous purge stream 116 may be vented from reactor 110 to preventbuildup of gaseous by-products and to maintain a set carbon monoxidepartial pressure at a given total reactor pressure. The temperature ofthe reactor may be controlled and the carbon monoxide feed is introducedat a rate sufficient to maintain the desired total reactor pressure.Gaseous purge stream 116 may be scrubbed with acetic acid and/ormethanol in recovery unit 117 to recover low boiling point components.The gaseous purge stream 116 may be partially condensed and thenon-condensable portion from recovery unit 117 may return low boilingpoint components to the top of reactor 110 via stream 118. Thenon-condensable portion may comprise methyl acetate, water, and/ormethyl iodide. Carbon monoxide in the gaseous purge stream may be ventedin line 109 or fed via line 119 to base of flasher 112 to enhancerhodium stability.

Carbonylation product is drawn off from carbonylation reactor 110 at arate sufficient to maintain a constant level therein and is provided toflasher 112 via stream 111. In flasher 112, the carbonylation product isseparated in a flash separation step with or without the addition ofheat to obtain a crude product stream 121 comprising acetic acid, and aliquid process stream 113, comprising a catalyst-containing solution.Aromatic compounds, if not removed, are concentrated in crude productstream 121. Generally, amine compounds are concentrated in liquidprocess stream 113 in the bottom of flasher 112 and substantially noamine compounds are carried over in crude product stream 121.

The catalyst-containing solution predominantly contains acetic acid, ametal compound of a carbonylation catalyst, e.g., a metal complex ofrhodium and/or iridium, and the iodide salt, along with lesserquantities of methyl acetate, methyl iodide, and water. In addition, thecatalyst-containing solution may contain minor amounts of corrosionmetal contaminants, such as compounds containing iron, nickel, chromium,molybdenum, and the like. In one embodiment, liquid process stream 113comprises corrosion metal contaminants in an amount from 0.025 wt. % to1.0 wt. %, based on metal content, e.g., from 0.025 wt. % to 0.5 wt. %or from 0.025 to 0.1 wt. %. The catalyst-containing solution may alsocontain minor amounts of amine compounds. In one embodiment, liquidprocess stream 113 comprises amine compounds in an amount from 0.001 wt.% to 1.0 wt. % based on nitrogen content, e.g., from 0.01 to 0.5 wt. %or from 0.05 wt. % to 0.3 wt. %. In liquid process stream 113, the molarratio of nitrogen in the amine to metal in the corrosion metalcontaminants may be greater than 3:1, e.g., greater than 5:1 or greaterthan 10:1.

Liquid process stream 113 may be initially combined with optional stream122 obtained from the bottoms of light ends column 123 in purificationsection 120, prior to being fed to exchange resin bed 114 via line 125.The bottoms of light ends column 123 in stream 120 may comprise aceticacid, a metal compound of a carbonylation catalyst, and impurities, suchas the corrosion metal contaminants. A portion of liquid process stream113 may be returned to reactor 110 via line 113′, thus bypassingexchange resin bed 114. Depending on the reaction conditions, the amountof liquid process stream 113 directed to exchange resin bed 114 may befrom 0.1 to 10% of the total mass flow of liquid process stream 113, andmore preferably about 1%. Depending on the size of the resin bed 114,increase flows from liquid process stream 113 may pass through resin bed114. The portion of liquid process stream 113 directed to exchange resinbed 114 is mixed with slipstream 124 to form aqueous stream 125. Aqueousstream 125 has a water concentration of greater than 50 wt. %, e.g.,greater than 60 wt. %, greater than 75 wt. % or greater than 85 wt. %,and creates a weakly acidic or non-acidic environment in exchange resinbed 114. In terms of ranges aqueous stream 125 may have a waterconcentration from 50 wt. % to 90 wt. %, e.g., from greater than 50 wt.% to 85 wt. % or from 60 wt. % to 85 wt. %. Slipstream 124 may be mixedcontinuously or as needed to dilute liquid process stream 113. In otherembodiments, slipstream 124 may be added directly to exchange resin bed114.

The resins useful for removing amine compounds, as well as corrosionmetal contaminants, from the process streams according to the presentinvention may include cation exchange resins either of the strong-acidor the weak-acid type. Both strong- and weak-acid type resins arereadily available as commercial products. The weak-acid cation exchangeresins are mostly copolymers of acrylic or methacrylic acids or estersor the corresponding nitriles, but a few of those marketed are phenolicresins. Preferably, strong-acid cation exchange resins are utilized.Strong-acid cation exchange resins predominantly comprise sulfonatedstyrene-divinylbenzene copolymers although some of the available resinsof this type are phenol-formaldehyde condensation polymers. Amberlyst™15 (Dow) and Purolite™ CT275 (The Purolite Company) are exemplarycommercial resins. Suitable resins may have a cation that corresponds tothe cation employed in the halogen promoter. For purposes ofillustrating the present invention, a cation exchange resin in itslithium form may be employed, such as those described in U.S. Pat. No.5,731,252, the disclosure of which is hereby incorporated by reference.

Gel-type resins or macroreticular-type resins are suitable but thelatter is preferred since organic components are present in the catalystsolutions being treated. Macroreticular resins are commonly employed inthe catalytic art and require minimal water to maintain their swellingproperties.

Contacting the catalyst-containing solution having corrosion metalcontaminants and amine compounds with the resin may be performed in astirred vessel wherein the resin is slurried with the catalyst solutionwith good agitation and the catalyst solution is then recovered bydecantation, filtration, centrifuging, etc. However, treatment of thecatalyst solutions is usually achieved by passing thecatalyst-containing solution through a fixed-bed column of the resin.The catalyst regeneration can be carried out as a batch, semi-continuousor continuous operation either with manual or automatic controlemploying methods and techniques well known in the art of ion-exchange.

The ion exchange treatment may be performed at temperatures ranging from0° C. to 120° C., e.g. from 20° C. to 90° C. Lower or highertemperatures are limited only by the stability of the resin to beemployed. Chromium removal may be more efficient at the highertemperatures. At the higher temperatures, a nitrogen or CO purge isdesirable. If temperatures above the boiling point of the catalystsolutions are employed, then operation under pressure may be required tomaintain the solution in the liquid phase. However, pressure is not acritical variable. Generally, atmospheric pressure or a pressureslightly above atmospheric is employed but superatmospheric orsubatmospheric pressures can be used if desired.

The rate of flow of liquid process stream 113 through exchange resin bed114 during removal of amine compounds and corrosive metals, in general,may vary from 1 to 50 BV/hr, e.g. from 1 to 35 BV/hr or more preferablyfrom 1 to 25 BV/hr. Depending on the resin and flow rate, higher bedvolumes may be possible. For purposes of the present invention, higherbed volumes, e.g., greater than 20 BV/hr, and short residence time inexchange resin bed 114 may also advantageously favor removal of aminecompounds.

Slipstream 124 may comprise methanol, water, methyl acetate, methyliodide, acetic acid, or mixtures thereof Slipstream 124 may be obtainedfrom outside of the carbonylation system. Preferably slipstream 124 issupplied by one or more of the other process streams from purificationsection 120 or reactant composition in line 107. There are severalavailable process streams to source slipstream 124. Examples ofslipstream sources include, but are not limited to, light phase 131,heavy phase 130, residue 154 from PRS 150, raffinate 158 from PRS 150,low-boiling point process stream 163 from vent scrubber 160, light phase145, heavy phase 146, and combinations thereof Preferable slipstreamsmay comprise dilute acetic acid such as light phase 131 and light phase145, which may be combined in part or whole with other streams.

In some embodiments, a portion of reactant composition in line 107,after aromatics are removed, may be used as slipstream 124. Whenreactant feed line 107 contains methanol, there may be amine compoundsas discussed above. Mixing a portion of reactant feed line 107 withliquid process stream 113 may also reduce the amine compounds inreactant feed line 107 prior to being fed to reactor 110. Optionally,the entire reactant feed line 107 may be fed as a slipstream 124 to formaqueous stream 125.

Resin bed 114 produces an outflow stream 115 comprising a purifiedprocess stream comprising a reduced amine content. Outflow stream 115 ispreferably returned to reactor 110. In one embodiment, outflow stream115 contains less corrosion metal contaminants and amine compounds thanaqueous stream 125 fed to resin bed 114. Higher water concentrations ofthe aqueous stream 125 tend to favor increased removal of corrosionmetal contaminants and amine compounds. Preferably, outflow stream 115has a reduced total corrosion metal and amine content. The reducedcorrosion metal content may be less than 1 wppm based on total weight ofoutflow stream 115. Preferably outflow stream 115 is substantially freeof corrosion metal contaminants. The reduced amine content may be lessthan 1 wppm based on total weight of outflow stream 115. In preferredembodiments, outflow stream 115 is substantially free of aminecompounds.

After contacting the bed with liquid process stream 113, washing orrinsing of resin bed 114 with water or the carbonylation product fromthe process from which the catalyst being treated is derived, such asacetic acid, may be desired to remove the rhodium from the resin bed.The rinsing or washing is effected at similar flow rates as in theremoval step.

After the resin has become exhausted, i.e., when the metal contaminantsbreak through into the effluent, the resin can be regenerated by passinga solution of organic salts, preferably lithium salts, therethrough.Optionally, a lithium salt is used in the regenerating cycle at aconcentration in the range from about 1 wt. % to about 20 wt. %.Quantities employed and regeneration procedures are well established inthe art and commonly recommended by the resin manufacturers. Aqueouslithium acetate is preferred as a regenerating agent since the acetateanion is employed in the reaction system and is readily available foruse. A further advantage is that its use eliminates the rinsing stepnormally required after the regeneration process when other regeneratesare employed. To maximize corrosion metal regeneration capacity and tomaximize resin bed column performance at relatively high concentrationsof lithium acetate, the lithium acetate regeneration solution shouldcontain some acetic acid, or product being produced, to avoid theformation of any insoluble corrosion metal compounds during theregeneration cycle. Precipitation of these compounds during theregeneration cycle may reduce the regeneration performance of the columnand also cause plugging of the resin bed. Typically, acetic acidconcentrations from about 0.1 to about 95 wt. % may be used, with aceticacid concentrations from about 0.1 to 20 wt. % being preferred.

The ion-exchange operation can be cyclic, where more than one resin bedis available for use. As the resin becomes exhausted in one resin bed,the slip stream of catalyst solution can be diverted to a fresh bedwhile the exhausted bed is subjected to regeneration.

Crude product stream 121 comprises acetic acid, methyl iodide, methylacetate, water, alkanes and permanganate reducing compounds (PRC's).Crude product stream 121, as well as subsequent derivative streams, maycontain corrosion metal contaminants that form downstream of flasher112. Crude product stream 121 contains substantially no aromatic and/oramine compounds.

Returning to the crude acetic acid product, crude product stream 121from flasher 112 is directed to purification section 120. In oneexemplary embodiment, purification section 120 preferably comprises alight ends column 123, a drying column 140, PRC removal system (PRS)150, and vent scrubber 160. Suitable purification sections may alsocomprise additional guard beds and/or heavy ends columns.

In one embodiment, light ends column 123 yields a low-boiling overheadvapor stream 126, a product side stream 127, and an optional bottomsstream 122. The temperature at the base of light ends column 123, i.e.,temperature of optional exiting bottoms stream 122, preferably is from120° C. to 170° C. In addition, the temperature at the top of the lightends column, i.e., temperature of low-boiling overhead vapor stream 126,preferably is from 100° C. to 145° C.

Low-boiling overhead vapor stream 126 may comprise methyl iodide, methylacetate, water, PRC's, acetic acid, alkanes, and dissolved gases. Asshown, low-boiling overhead vapor stream 126 preferably is condensed anddirected to an overhead phase separation unit, as shown by overheaddecanter 128. Conditions are desirably maintained such that thecondensed low-boiling overhead vapor stream 126, once in decanter 128,will separate into a light phase and a heavy phase. The light phase andheavy phase are withdrawn via lines 129 and 130, respectively, and thesestreams are also referred to as process streams.

Light phase stream 129 preferably comprises water, acetic acid, andPRC's, as well as methyl iodide and methyl acetate. As shown in FIG. 1,light phase stream 129 may be refluxed to light ends column 122. Aportion of light phase stream 129 may also be separated and processed ina PRS 150 to remove PRC's. PRC's may include, for example, compoundssuch as acetaldehyde, acetone, methyl ethyl ketone, butyraldehyde,crotonaldehyde, 2-ethyl crotonaldehyde, 2-ethyl butyraldehyde and thelike, and the aldol condensation products thereof

Optionally, a portion of light phase stream 129 may also be returned tocarbonylation reactor 110 via stream 131. When returned to reactor 110,light phase stream 131 may be fed to exchange resin bed 114 asslipstream 124. Heavy phase stream 130 from decanter 128 can beconveniently recirculated, either directly or indirectly, to reactor110. A portion of heavy phase stream 130 may be fed as slipstream 124 toexchange resin bed 114 and preferably in combination with light phasestream 131. Optionally, a portion of the heavy phase 130 may berecirculated to reactor 110, with a slip stream (not shown), generally asmall amount, e.g., from 5 to 40 vol. %, or from 5 to 20 vol. %, ofheavy phase 130 being directed to PRS 150.

PRS 150 comprises a column 151 and extractor 152. Column 151 yields avapor overhead stream 153 and a bottom process stream 154. Bottomprocess stream 154 comprises water, methyl acetate, methanol andmixtures thereof A portion of bottom process stream 154 may be fed asslipstream 124 to exchange resin bed 114. Overhead stream 153 may beenriched in at least one PRC and may also contain methyl iodide.Overhead stream 153 is condensed and collected in an accumulator. Aportion of condensed overhead stream 153 can be refluxed back to column151 via stream 155. The remaining portion of condensed overhead streamis fed to extractor 152 via stream 156. In one embodiment, stream 156may contain methanol and methyl acetate at a combined concentration ofless than about 10 wt. %, e.g., less than about 5 wt. %, less than about2 wt. %, or less than about 1.5 wt. %. Also stream 156 may contain lessthan about 3 wt. % acetic acid, e.g., less than about 1 wt. %, or lessthan about 0.5 wt. %.

Extraction with an aqueous stream 157, such as water, may be either asingle stage or multistage extractor and any equipment used to conductsuch extractions can be used in the practice of the present invention.Multistage extraction is preferred. For example, extraction can beaccomplished by combining stream 156 with aqueous stream 157 andproviding the combination successively to a mixer and then a separator.Multiple such combinations of mixer and separator can be operated inseries to obtain a multistage extraction. Multistage extraction may beaccomplished in a single vessel having a series of trays. The vessel maybe equipped with paddle(s) or other mechanisms for agitation to increaseextraction efficiency.

The mutual solubility between the two phases in the extraction canincrease with temperature. Accordingly, it is desirable that theextraction be conducted at a combination of temperature and pressuresuch that the extractor contents can be maintained in the liquid state.Moreover, it is desirable to minimize the temperatures to which stream156 is exposed to minimize the likelihood of polymerization andcondensation reactions involving acetaldehyde. Water used in theextraction is desirably from an internal stream so as to maintain waterbalance within the reaction system. Dimethyl ether (DME) can beintroduced to the extraction to improve the separation of methyl iodidein the extraction, i.e., to reduce the loss of methyl iodide into thewaste stream 159. The DME can be introduced to the process or formed insitu.

In extractor 152, stream 156 is desirably provided proximate to one endof the vessel with aqueous stream 157 being provided proximate to theother end of the vessel or such other location to obtain acountercurrent flow. A waste stream 159 comprising the at least one PRC,namely acetaldehyde, is extracted by the water. Waste stream 159, insome embodiments, may strip acetaldehyde and recirculate water to theprocess. Raffinate, notably containing methyl iodide is withdrawn fromextractor 152 as a process stream 158. A portion of raffinate 158 may befed as slipstream 124 to exchange resin bed 114.

PRC removal columns are further described in U.S. Pat. Nos. 6,143,930,6,339,171, and 7,223,886, and U.S. Pub. Nos. 2005/0197513, 2006/0247466,and 2006/0293537, the disclosures of which are hereby incorporated byreference. An exemplary two-stage distillation PRS comprising one ormore extractors is described in U.S. Pat. No. 7,223,886. An exemplarysingle stage PRS, similar to those shown in FIG. 1, is described in U.S.Pub. No. 2006/0247466.

Product side stream 127 from the light ends column may comprise aceticacid and water. Product side stream 127 preferably is in the liquidphase and is withdrawn from the light ends column 123 at a temperaturefrom 115° C. to 160° C., e.g., from 125° C. to 155° C. A portion ofstream 127 may be returned to light ends column 123 via a sidecondenser.

Drying column 140 separates product side stream 127 to yield an overheadstream 141 comprised primarily of water and a dried product stream 142.The dried purified product stream 142 preferably comprises acetic acidin an amount greater than 90 wt. %, e.g., greater than 95 wt. % orgreater than 98 wt. %. The temperature at the base of drying column 140,i.e., temperature of the exiting dried purified product stream 142,preferably is from 115° C. to 185° C., 130° C. to 180° C., e.g., from140° C. to 175° C. The temperature at the top of drying column 140,i.e., temperature of overhead stream 141, preferably is from 90° C. to150° C., 100° C. to 150° C., e.g., from 110° C. to 145° C. In someembodiments, the pressure in drying column 140 is from 2 bar to 7 bar,e.g., 3 bar to 6 bar, or 4 bar to 5 bar. Optionally, dried purifiedproduct stream 142 may be further treated in one or more guard beds (notshown) and/or heavy end columns (not shown) to further removeimpurities, such as halides, or heavier acids and/or esters.

Overhead stream 141 of the drying column may be cooled and condensed inan overhead receiver 143 to form a light phase and a heavy phase. Aportion of the light phase from receiver 143 may be refluxed to dryingcolumn 140 via line 144. The remaining portion of light phase 145 may bea process stream and fed to exchange resin bed 114 as slipstream 124.Heavy phase 146 is also a process stream that may be returned to reactor110. A portion of heavy phase 146 may be fed as slipstream 124 toexchange resin bed 114. The condensed overhead stream 141, either aslight phase 145 or heavy phase 146, is preferably used as slipstream 124because both streams contain relatively high amounts of water.

Non-condensable gases from decanter 128 may be removed by vent stream133 and treated in vent scrubber 160. A scrubbing solvent 161,preferably chilled to less than 25° C., may be fed to vent scrubber 160to scrub vent stream 133 of low boiling point components, such as methyliodide, which are removed as a process stream via line 163. A portion oflow boiling point components in line 163 may be fed as slipstream 124 toexchange resin bed 114. Scrubbing solvents include methanol, methylacetate, dimethyl ether, acetic acid and mixtures thereof The overheadsof recovery unit 160 may exit as purge gas 164 that comprises carbonmonoxide and other inert gases.

Although FIG. 1 illustrates processing the catalyst-containing solutionin line 113 from flasher 112 being treated to remove amines, otherprocess streams described above may also be treated in one or moreexchange resins to remove corrosive metals and/or amine compounds.

FIG. 1 depicts embodiments in which aromatic compounds are removed priorto the carbonylation reactor and amine compounds are removed in thepresence of corrosion metal contaminants. FIG. 2 shows anotherembodiment in which aromatic compounds and amine compounds in thereactant feed stream 101 are removed prior to the carbonylation reactor110. For clarity, the recovery unit 117 and purification section 120 arenot illustrated in FIG. 2.

As previously indicated, reactant feed stream 101 may comprise lowgrades of methanol that contain amine compounds. The reactant feedstream 101 may also contain aromatic compounds. As discussed above inFIG. 1, gas chromatographer 102 measures aromatic concentration and thecarbonylation process 100 determines whether to direct reactant feedstream 101 via line 104 or line 105. When aromatics are detected, thereactant feed stream in line 105 may be treated in guard bed 103 ordiluted with a stream 106 to form reactant composition 107. The reactantcomposition is fed to exchange resin bed 170. Exchange resin bed 170 maybe similar to the exchange resins described in this application.Typically there are no corrosion metal contaminants in reactantcomposition 107 and reactant composition 107 is generally non-acidic. Asolvent, such as an aqueous slipstream, may be added to exchange resinbed 170. Exchange resin bed 170 produces an outflow 171 that is fed toreactor. The reduced amine content may be less than 1 wppm based ontotal weight of outflow stream 171 and more preferably outflow stream171 is substantially free of aromatic and amine compounds.Advantageously, reaction solution 111 withdrawn from reactor 110 may besubstantially free of aromatic and amine compounds. Thus, no aminecompounds in the form of iodide salts build up in flasher 112. Also,exchange resin bed 114 in FIG. 2 may be used to remove corrosion metalcontaminants.

Slipstream 124 in FIG. 2 is optional and may contain acetic acid tocreate an acidic environment to favor removal of corrosion metalcontaminants when reaction solution 111 is substantially free of aminecompounds. In preferred embodiments, exchange resin bed 170 may be sizedto process the entire flow from reactant feed stream. However, it may benecessary to by-pass exchange resin bed 170 via line 172 to maintainreaction conditions. When reactant feed line 172 by-passes exchangeresin bed 170, optional slipstream 124 may be added to create an aqueousstream 125 having a water concentration of greater than 50 wt. %.

One of ordinary skill in the art having the benefit of this disclosurecan design and operate the distillation columns described herein toachieve the desired results of the present invention. Such efforts,although possibly time-consuming and complex, would nevertheless beroutine for one of ordinary skill in the art having the benefit of thisdisclosure. Accordingly, the practice of this invention is notnecessarily limited to specific characteristic of a particulardistillation column or the operation characteristics thereof, such asthe total number of stages, the feed point, reflux ratio, feedtemperature, reflux temperature, column temperature profile, and thelike.

In order that the invention disclosed herein may be more efficientlyunderstood, an example is provided below. It should be understood thatthese examples are for illustrative purposes only and is not to beconstrued as limiting the invention in any manner.

EXAMPLES Example 1

15.9 g of a methanol feed containing 78 wppm of xylenes was pretreatedin accordance with an embodiment of the present invention by passing themethanol to a guard bed containing an adsorbent. Each of the absorbentswas granular activated carbon and included: Fisherbrand™ ActivatedCarbon Charcoal 6 to 14 mesh, Calgon SGL™ 8×30 and Calgon CAL™ 12×40. Ablank was also tested. The type of adsorbent and loading of adsorbent isshown in Table 1 below. Samples were taken after the guard bed todetermine the amount of xylenes left. The guard bed was maintained at atemperature from 20° C. to 35° C. The results in Table 1 demonstrate theeffectiveness in reducing xylenes concentration using activated carbonadsorbents.

TABLE 1 % of Xylenes Xylenes Remaining Adsorbent Absorbent Wt. (g)Removed (wppm) Blank 0   0% 78 Fisherbrand 0.04 26.9% 57 Fisherbrand 0.1  50% 39 Fisherbrand 0.21 71.8% 22 Fisherbrand 0.25 76.9% 18 Fisherbrand0.5 93.6% 5 SGL 8 × 30 0.04 19.2% 63 SGL 8 × 30 0.15   41% 46 SGL 8 × 300.2 60.3% 31 SGL 8 × 30 0.25 64.1% 28 SGL 8 × 30 0.49 88.5% 9 CAL 12 ×40 0.04 23.1% 60 CAL 12 × 40 0.1 51.3% 38 CAL 12 × 40 0.15 62.8% 29 CAL12 × 40 0.2 74.4% 20 CAL 12 × 40 0.26 79.5% 16 CAL 12 × 40 0.49 94.9% 4

Example 2

A nonvolatile residue (NVR) test was used to determine the amount ofnon-volatiles that would deadsorb off of the adsorbent when exposed tomethanol. The adsorbents were immersed in methanol and filtered off NVRwas measured by evaporating methanol. The results for the adsorbentsused in Example 1 are shown in Table 2.

TABLE 2 Adsorbent MeOH Wt. MeOH in NVR NVR Wt. Adsorbent Wt. (g) (g)Test (g) (mg) CAL 12 × 40 15 45 20.1 1.5 SGL 8 × 30 30 90 49.1 <0.001Fisherbrand 30 90 45.7 101.4

CAL 12×40 was further tested by repeating the methanol immersion. CAL12×40 was immersed in 180 g of methanol and filtered off The results forCAL 12×40 are shown in Table 3.

TABLE 3 Adsorbent MeOH in NVR NVR Wt. Adsorbent Wt. (g) MeOH Wt. (g)Test (g) (mg) CAL 12 × 40 60 180 79.1 1.3 mg CAL 12 × 40 60 180 79.1<0.1 mg  CAL 12 × 40 60 180 79.1 0.3 mg

While the invention has been described in detail, modifications withinthe spirit and scope of the invention will be readily apparent to thoseskilled in the art. All publications and references discussed above areincorporated herein by reference. In addition, it should be understoodthat aspects of the invention and portions of various embodiments andvarious features recited may be combined or interchanged either in wholeor in part. In the foregoing descriptions of the various embodiments,those embodiments which refer to another embodiment may be appropriatelycombined with other embodiments as will be appreciated by one skilled inthe art. Furthermore, those skilled in the art will appreciate that theforegoing description is by way of example only, and is not intended tolimit the invention.

1-21. (canceled)
 22. A carbonylation process for producing a carbonylation product having a low aromatic content, the process comprising: contacting a reactant composition that comprises (i) a reactant selected from the group consisting of methanol, methyl acetate, methyl formate, dimethyl ether, and mixtures thereof and (ii) an aromatic compound selected from the group consisting of benzene, toluene, xylenes, ethylbenzene, naphthalene, benzene derivatives, and mixtures thereof, with a guard bed that comprises activated carbon to form a de-aromatic reactant composition; reacting carbon monoxide with the de-aromatic reactant composition in a reactor containing a reaction medium to produce a reaction solution comprising acetic acid, and wherein the reaction medium comprises water, acetic acid, methyl acetate, methyl iodide, and a catalyst; and withdrawing a reaction solution from the reactor.
 23. The process of claim 22, wherein the reaction solution comprises less than 40 wppm aromatic compounds, based on the total weight of the reaction solution.
 24. The process of claim 22, wherein at least 6 milligrams of the activated carbon is used for each gram of the reactant composition.
 25. The process of claim 22, wherein the reactant composition comprises at least 1 wppm aromatic compounds, based on total weight of the reactant composition.
 26. The process of claim 22, wherein the de-aromatic reactant composition comprises less than 40 wppm the aromatic compounds, based on total weight of the de-aromatic reactant composition.
 27. A carbonylation process for producing an acetic acid product having a low aromatic content, the process comprising: contacting a reactant composition that comprises (i) a reactant selected from the group consisting of methanol, methyl acetate, methyl formate, dimethyl ether, and mixtures thereof; (ii) an aromatic compound selected from the group consisting of benzene, toluene, xylenes, ethylbenzene, naphthalene, benzene derivatives, and mixtures thereof; (3) an amine compound, with a guard bed that comprises an adsorbent to form a de-aromatic reactant composition; reacting carbon monoxide with the de-aromatic reactant composition in a reactor containing a reaction medium that comprises water, methyl acetate, methyl iodide, and a catalyst to produce a reaction solution comprising acetic acid; and recovering the acetic acid product from the reaction solution.
 28. The process of claim 27, wherein the reactant composition comprises from 1 to 800 wppm aromatic compounds, based on total weight of the reactant composition.
 29. The process of claim 27, wherein the reaction solution comprises less than 40 wppm aromatic compounds, based on total weight of the de-aromatic reactant composition.
 30. The process of claim 27, wherein the adsorbent is selected from the group consisting of activated carbon, zeolites, activated amorphous clays, metal oxides, and silicaceous adsorbents.
 31. The process of claim 27, wherein at least 6 milligrams of the adsorbent is used for each gram of the reactant composition.
 32. The process of claim 27, wherein the de-aromatic reactant composition has a lower concentration of the aromatic compounds than the reactant composition.
 33. The process of claim 27, wherein at least 40% of the aromatic compounds are removed by the guard bed.
 34. The process of claim 27, wherein the guard bed is adjacent to an inlet for the reactor.
 35. The process of claim 27, wherein the amine compound is selected from the group consisting of trimethylamine, triethylamine, dimethylethyl amine, diethylmethyl amine, diethylpropylamine, tri-n-propylamine, triisopropylamine, ethyldiisopropylamine, tri-n-butylamine, triisobutylamine, tricyclohexylamine, ethyldicyclohexylamine, N,N-dimethylaniline, N,N-diethylaniline, and benzyldimethylamine.
 36. The process of claim 27, further comprising contacting the de-aromatic reactant composition with an exchange resin to produce a purified de-aromatic reactant composition having a reduced amine content.
 37. The process of claim 36, wherein the purified de-aromatic reactant composition comprises less than 1 wppm amine, based on total weight of the purified de-aromatic reactant composition.
 38. The process of claim 36, wherein recovering the acetic acid product from the reaction solution comprises flashing the reaction solution into a carbonylation product comprising acetic acid and a liquid process stream comprising the amine compounds.
 39. The process of claim 36, wherein the liquid process stream comprises one or more corrosion metals.
 40. A carbonylation process for producing a carbonylation product having a low aromatic content, the process comprising: measuring a concentration of aromatic compounds in a reactant composition, wherein the reactant is selected from the group consisting of methanol, methyl acetate, methyl formate, dimethyl ether, and mixtures thereof; contacting the reactant composition with a guard bed that comprises an adsorbent when the measured concentration of aromatic compounds is more than 1 wppm to form a de-aromatic reactant composition having less than 40 wppm aromatic compounds, provided that the concentration of the aromatic compounds of the de-aromatic reactant composition is less than that the concentration of the aromatic compounds of the reactant composition; reacting carbon monoxide with the de-aromatic reactant composition in a reactor containing a reaction medium to produce a reaction solution; flashing the reaction solution into a carbonylation product comprising acetic acid and a liquid process stream comprising amine compounds and one or more corrosion metals; contacting a portion of the liquid process stream with an exchange resin bed to remove the amine compounds and one or more corrosion metals; and recovering an acetic acid product from the carbonylation product.
 41. The process of claim 40, wherein the aromatic compounds are measured using an on-line analyzer selected from the group consisting of gas chromatography, and UV spectrophotometry. 